STEEL ARTICLE HAVING HIGH HARDNESS AND IMPROVED TOUGHNESS AND PROCESS FOR FORMING THE ARTICLE

Description

Technical Field

[0001] This invention relates generally to a steel article having both high particle hardness and improved toughness characteristics and to a method performing such an article, and more particularly to a steel article and method by which a plurality of carbides are dispersed in a lower bainitic matrix on selected surfaces of the article.

Background Art

[0002] Carburized components typically exhibit high hardness and low to moderate toughness. It is well known that one method of increasing the contact fatigue and scoring resistance of a conventionally carburized component is to utilize processes which form hard particles such as carbides in the surface microstructure, such as the process disclosed in U.S. Patent 4,921,025 by Tipton et al. and assigned to the assignee of the present invention.

[0003] It is also well known that one method to increase toughness is to carburize and then austemper to produce a tougher case microstructure consisting primarily of lower bainite. This process of carburizing and austempering is commonly referred to as Carbo-Austempering, and is known to increase the toughness of carburized components because at an equivalent hardness, a bainitic microstructure is tougher than a conventional martensitic microstructure. However, the accompanying hardness reduction results in undesirable lowering of wear, contact fatigue, and scoring resistance.

[0004] Carbo-Austempering of low and medium carbon steels is described in an article by W.R. Keough, titled Carbo-Austempering, published in 1995, (Carburizing and Nitriding with Atmospheres, Proceedings of the second International Conference on Carburizing and Nitriding with Atmospheres, December, 1995, ASM International). However, it is commonly known by those skilled in the art that austempering of low and medium carbon steels, such as SAE 8615, SAE4211, and SAE4150, effectively increases toughness, but result in lower surface hardness.

[0005] Steel articles produced by the process described in the above-references U.S. Patent 4,921,025 have a plurality of carbides formed on the surface which provide high surface hardness. However, the articles, even though formed of lower to medium carbon steel, have relatively low toughness properties because the carbides are distributed in primarily a martensitic case microstructure.

[0006] It is therefore desirable to have a steel article, and a method of forming the article, that has both high surface hardness and higher toughness, without having a high core carbon content or the addition of relatively expensive carbide forming elements.

[0007] US-A-4,202,710 discloses a method carbonising low alloy steel as a carbon content of no more than 0.5%.

[0008] Various aspects of this invention are defined in the independent claims. Some preferred features are defined in the dependent claims.

[0009] A more complete understanding of the article and method of the present invention may be had by reference to the following detailed description when taken in conjunction with the accompanying single drawing which is a graphical representation of the time and temperature relationship of the carburizing and hardening process embodying the present invention.

[0010] The present invention is specifically directed to a method of forming steel articles containing higher hardness carbide particles and having higher toughness from low medium carbon, i.e., from 0.08% to 0.35% carbon, steel. In the following described examples, test samples were formed of a modified version of SAE 4122 steel, a steel hardenable by carburizing, and having a composition as listed in Table 1.

TABLE I

COMPOSITION BY WEIGHT PERCENT
Element	SAE 4122
Carbon	0.21
Manganese	0.95
Silicon	0.02
Phosphorus	0.01
Sulfur	0.025
Chromium	0.97
Nickel	0.06
Molybdenum	0.42
Aluminum	0.28
Copper	0.06
Titanium	0.001

[0011] Four samples of a steel material having the above composition were prepared for testing. The first test sample was subjected to a conventional carburizing and hardening treatment. A second sample was conventionally carburized and then austempered. A third sample was treated, in accordance with the process described in U.S. Patent 4,921,025, to form a plurality of surface carbides on the exposed surfaces of the sample. The referenced process is specifically directed to forming a surface having a high density of carbides in a predominately martensitic matrix. The fourth sample, embodying the article and method of the present invention, was carburized in accordance with the process outlined in U.S. Patent 4,921,025 to form a plurality of carbides on the exposed surfaces of the article, and then austempered.

[0012] The four test samples were prepared in accordance with ASTM Standard E 23 for impact testing. More specifically, each sample was about 55 millimeters long and had a 10 millimeter square cross section. In accordance with accepted procedure for impact testing of surface or case hardened materials, the samples were not notched. When tested on a Charpy Impact tester at room temperature (about 25° C) the respective impact values were recorded and listed below in Table II. For sample Nos. 1 and 2, the maximum particle hardness was measured on a microhardness tester. For sample Nos. 3 and 4, the carbide hardness was measured directly using a nanoindentor. The measured hardness and toughness values for the respective test samples are listed in Table II:

TABLE II

Sample No. (Composition Shown in Table I)	Toughness Charpy Unnotched @ 25° C; Joules (ft-lbs)	Hardness Maximum Particle Hardness (Equiv. Knoop, 500 gram)	Comment
1. Conventional carburizing and hardening	28 (21)	754	Problem - low toughness and absence of hard particles results in lower impact strength and lower wear, contact fatigue and scoring resistance
2. Carburizing and austempering	100 (74)	688	Problem - improved toughtness but low hardness results in higher impact strength but still have lower wear, contact fatigue and scoring resistance
3. Carbide producing process per U.S. Patent 4,921,025 issued May 1, 1990	20 (15)	1400	Problem - high particle hardness results in higher wear, contact fatigue and scoring resistance, but low toughness results in low impact strength
4. Carbide producing process per U.S. Patent 4,921,025 and austempering	87 (64)	1400	Solution - high particle hardness and improved toughness results in higher wear, contact fatigue. scoring resistance and also higher impact strength

[0013] As described above, the test samples were all formed of the above-identified modified SAE 4122 steel, representing a low to medium carbon steel. Samples 1 and 2 were subjected to a conventional carburizing treatment to form a high carbon case with no surface carbides. Sample 1 exhibited a low toughness of 28 Joules, typical of conventional carburizing and hardening. Test sample 2 was austempered to provide a lower bainitic matrix surface microstructure and exhibited the highest toughness of 100 Joules; however the corresponding reduction in hardness is undesirable for wear, contact fatigue, and scoring resistance.

[0014] Test Sample Nos. 3 and 4 were treated in accordance with the process described in the above-referenced, U.S. Patent 4,921,025. Test Sample Nos. 3 and 4 were carburized at a temperature, and for a period of time, in an atmosphere having a carbon potential sufficient to form carbides and austenite on the surface of the sample. More specifically, as described in greater detail in the aforementioned U.S. Patent 4,921,025, the processing of SAE 4122 steel Samples 3 and 4 included a first stage carburizing cycle in which the test pieces were placed in the pre-heated furnace in which the carbon potential of the gas atmosphere in the furnace was maintained at a level about equal to the saturation limit of carbon in austenite at the furnace temperature. The test pieces were held in the furnace, under those conditions, for a period sufficient to form 75% to 95% of the final case depth. Test pieces 3 and 4 were gas quenched, after the first stage, at a rate sufficient to suppress carbide nucleation on the carburized surface. The gas quench was continued until the temperature of the test piece was reduced to a temperature below the Ar₁ temperature to assure the substantially complete transformation to bainite and/or pearlite. Each of the test Samples 3 and 4 were then further carburized in a second stage in which the test pieces were placed in a pre-heated furnace in which the carbon content was maintained at a level greater than the saturation limit of carbon in austenite at the furnace temperature. Test pieces 3 and 4 were held in the furnace during the second stage carburizing for a period of time sufficient to form a high density of surface carbides dispersed in austenite. Test Sample 3 was then quenched to transform the surface to a microstructure of martensite, retained austenite and carbides, as taught in U.S. Patent 4,921,025. Test Sample 3 has high particle hardness resulting in higher wear, contact fatigue and scoring resistance, but the low toughness, as shown in Table II, results in lower impact strength.

[0015] As illustrated in the sole drawing figure, Test Sample No. 4 was quenched to a temperature below the Ar₁ temperature and above the M_S temperature (the temperature at which martensite begins to form) and held at that temperature for a time sufficient to form at least about 70% of the austenite in the surface microstructure to lower bainite. Desirably, the article is held at a temperature about 25° C (45° F) above the M_S temperature of the material. In the herein described test, Test Sample No. 4 was held at about 260° C (500° F) for about two hours and then cooled to room temperature. The surface area of Test Sample No. 4 was examined and found to contain about 22% carbides, i.e., carbides comprised about 22% of the surface area of sample. Desirably, in an article formed in accordance with the present invention, a quantifiable preselected area of the article will contain at least about 20% carbides dispersed in a predominately lower bainitic matrix.

[0016] Importantly, as shown in Table II, Test Sample No. 4, having a plurality of surface carbides disbursed in a predominantly lower bainitic matrix exhibited both high hardness and surprising high toughness for a sample with a plurality of embrittling carbides.

[0017] Based on the above tests, it is now believed that low to medium carbon steels, containing from 0.8% to 0.35% carbon, and preferably having silicon content less than about 0.10% and a chromium content less than about 1.1% are suitable materials for use in the above-described process whereby a plurality carbides are dispersed within a predominantly lower bainitic matrix. In particular, the steel material specifically defined in

[0018] U.S. Patent 4,921,025 in which the steel material comprises, by weight percent, of from about 0.08 to about 0.35 carbon, from about 0.3 to about 1.7 manganese, less than about 0.10 silicon, less than about 1.1 chromium, from about the 0.2 to about 2.5 carbide forming elements including chromium, less that than 6.0 additional hardenability agents, less than 1.0 grain refining elements, and not more than about 0.15 copper, with the balance being iron and trace impurities, is particularly suitable for forming steel articles having high toughness and high particle hardness in accordance with the method embodying the present invention.

[0019] Also, as is demonstrated herein, articles of a steel material represented by modified SAE 4122 steels having a composition, by weight percent, of from about 0.19 to about 0.23 carbon, from about 0.80 to about 1.10 manganese, no more than about 0.02 phosphorus, from about 0.015 to about 0.025 sulphur, no more than about 0.10 silicon, from about 0.45 to about 1.00 chromium, from about 0.18 to about 0.45 molybdenum, no more than about 0.10 nickel, no more than about 0.10 copper, no more than about 0.02 titanium, when carburized and austempered in accordance with the present invention to provide a plurality of surface carbides dispersed in a predominately lower bainitic matrix, exhibits unexpectedly higher toughness.

[0020] Although the present invention is described in terms of a preferred exemplary embodiment, with specific reference to SAE 4122 steel, those skilled in the art will recognize that other low to medium carbon steels which can be carburized to form a plurality of carbides on all or pre-selected surfaces of the article, may be made without departing from the invention.

Claims

1. A method of forming a steel article from a steel material that is hardenable by carburizing and containing, by weight percent, from 0.08 to 0.35 carbon, the method comprising:

carburizing said article at a temperature and for a period of time in an atmosphere having a carbon potential sufficient to form at least one preselected surface area on said article comprising carbides and austenite;

quenching said carburized article; and the step of quenching involving quenching the article to a temperature below the Ar₁ temperature and above the M_s temperature of the steel material; and

holding the article at a temperature below the Ar₁ temperature and above the M_s temperature for a time sufficient to transform at least about 70% of said austenite in the preselected surface area microstructure to lower bainite.

2. A method of forming a steel article as claimed in claim 1, wherein said step of quenching includes forming at least about 20% carbides on the preselected surface having a matrix microstructure consisting of at least about 70% lower bainite.

3. A method as claimed in claim 1 or claim 2, wherein the step of carburizing involves:

carburizing the article in a first stage;

cooling the article to below the Ar₁ temperature; and

carburizing the article again in an atmosphere with a carbon content at a level greater than the saturation limit of carbon in austenite.

4. A method as claimed in claim 3 in which the step of cooling involves gas quenching the article.

5. A method as claimed in claim 4, wherein the gas quenching is done at a rate sufficient to suppress carbide nucleation on the carburized surface.

6. A method as claimed in any one of the preceding claims, wherein in the step of holding the temperature of the article, the temperature is held at substantially 25C above the M_s temperature.

7. A carburized steel article made from a steel material that is hardenable by carburizing and contains, by weight percent, from 0.08 to 0.35 carbon and no more than 0.10 percent silicon, the article having a microstructure that is characterised by a plurality of surface carbides on at least one preselected surface of the article, the surface carbides being dispersed in a lower bainitic matrix.

8. An article as claimed in Claim 7, wherein said steel material contains less than about 1.1 percent chromium.

9. An article as claimed in Claim 7 or Claim 8, wherein said steel material comprises, by weight percent, from 0.08% to 0.35% carbon, from 0.3% to 1.7% manganese, less than about 0.10% silicon, less than about 1.1% chromium, from 0.2% to about 2.5% carbide forming elements including said chromium, less than 6% additional hardenability agents, less than about 1% grain refining elements, not more than about 0.15% copper, and the balance iron and trace impurities.

10. An article as claimed in any one of Claims 7 to 9, wherein said surface carbides have an equivalent Knoop 500 gram maximum particle hardness of at least about 900, and an unnotched sample of said article prepared in accordance with ASTM Standard E23 has a toughness of at least 50 Joules as measured on a Charpy impact tester at 25°C.

11. An article as claimed in any one of claims 7 to 10, wherein the pre-selected surface area contains at least about 20% carbides dispersed in a matrix that comprises at least 70% lower bainite.

Ansprüche

1. Ein Verfahren zum Formen eines Stahlgegenstands aus einem Stahlmaterial, das durch Karburierung härtbar ist und zwischen 0,08 und 0,35 Gewichtsprozent Kohlenstoff enthält, wobei das Verfahren aus Folgendem besteht:

Karburieren des Gegenstands bei einer gewissen Temperatur und über einen gewissen Zeitraum hinweg bei einer Atmosphäre mit einem Kohlenstoffpotential, das ausreicht, um mindestens einen vorgewählten Oberflächenbereich auf dem Gegenstand, bestehend aus Carbiden und Austenit, zu formen;

Abschrecken des karburierten Gegenstands; und wobei der Schritt des Abschreckens das Abschrecken des Gegenstands auf eine Temperatur, die unter der Ar₁-Temperatur und über der M_s-Temperatur des Stahlmaterials liegt, einschließt; und

Halten des Gegenstands bei einer Temperatur unter der Ar₁-Temperatur und über der M_s-Temperatur für eine Zeitdauer, die ausreicht, um mindestens ungefähr 70 % des Austenits in der vorgewählten Oberflächenbereich-Mikrostruktur in unteren Bainit umzuwandeln.

2. Verfahren zum Formen eines Stahlgegenstands gemäß Anspruch 1, wobei der Schritt des Abschreckens das Formen von mindestens ungefähr 20 % Carbiden auf dem vorgewählten Oberflächenbereich mit einer Matrix-Mikrostruktur, die aus mindestens ungefähr 70 % unterem Bainit besteht, beinhaltet.

3. Verfahren gemäß Anspruch 1 oder Anspruch 2, wobei der Schritt des Karburierens Folgendes einschließt:

Karburieren des Gegenstands in einer ersten Stufe;

Auskühlen des Gegenstands auf unter die Ar₁-Temperatur; und

nochmaliges Karburieren des Gegenstands bei einer Atmosphäre mit einem höheren Grad an Kohlenstoffgehalt als die Sättigungsgrenze von Kohlenstoff in Austenit.

4. Verfahren gemäß Anspruch 3, wobei der Schritt des Auskühlens das Abschrecken des Gegenstands mit Gas einschließt.

5. Verfahren gemäß Anspruch 4, wobei das Abschrecken mit Gas bei einer Geschwindigkeit durchgeführt wird, die ausreicht, um die Kristallisationskeimbildung von Carbid auf der karburierten Fläche zu unterdrücken.

6. Verfahren gemäß einem der vorhergehenden Ansprüche, wobei in dem Schritt des Haltens der Gegenstand-Temperatur die Temperatur bei im Wesentlichen 25 °C über der M_s-Temperatur gehalten wird.

7. Ein karburierter Stahlgegenstand, der aus einem Stahlmaterial hergestellt ist, das durch Karburierung härtbar ist und zwischen 0,08 und 0,35 Gewichtsprozent Kohlenstoff und nicht mehr als 0,10 Prozent Silizium enthält, wobei der Gegenstand eine Mikrostruktur aufweist, die durch eine Vielzahl von Oberflächen-Carbiden auf mindestens einer vorgewählten Oberfläche des Gegenstands gekennzeichnet ist, wobei die Oberflächen-Carbide in einer unteren Bainit-Matrix dispergiert sind.

8. Gegenstand gemäß Anspruch 7, wobei das Stahlmaterial weniger als ungefähr 1,1 Prozent Chrom enthält.

9. Gegenstand gemäß Anspruch 7 oder Anspruch 8, wobei das Stahlmaterial aus zwischen 0,08 Gew.-% und 0,35 Gew.-% Kohlenstoff, zwischen 0,3 Gew.-% und 1,7 Gew.-% Mangan, weniger als ungefähr 0,10 Gew.-% Silizium, weniger als ungefähr 1,1 Gew.-% Chrom, zwischen 0,2 Gew.-% und 2,5 Gew.-% Carbid formenden Elementen, einschließlich Chrom, weniger als 6 Gew.-% zusätzlichen Härtbarkeits-Agenzien, weniger als ungefähr 1 Gew.-% Kornverfeinerungs-Elementen, nicht mehr als ungefähr 0,15 Gew.-% Kupfer und den restlichen Eisen- und Spurenunreinheiten besteht.

10. Gegenstand gemäß einem der Ansprüche 7 bis 9, wobei die Oberflächen-Carbide eine entsprechende maximale 500 g Knoop-Partikelhärte von mindestens 900 aufweisen und wobei eine gemäß dem ASTM-Standard E23 zubereitete ungekerbte Probe des Gegenstands eine wie im Kerbschlagbiegeversuch nach Charpy bei 25 °C gemessene Härte von mindestens 50 Joule aufweist.

11. Gegenstand gemäß einem der Ansprüche 7 bis 10, wobei der vorgewählte Oberflächenbereich mindestens ungefähr 20 % Carbide, die in einer Matrix, bestehend aus mindestens 70 % unterem Bainit, dispergiert sind, enthält.

Revendications

1. Un procédé pour former un article en acier à partir d'un matériau en acier qui est durcissable par cémentation et contenant, en pourcentage en poids, de 0,08 à 0,35 de carbone, le procédé comprenant :

la cémentation dudit article à une certaine température et pendant une certaine durée dans une atmosphère ayant un potentiel carbone suffisant pour former au moins une aire présélectionnée sur ledit article comprenant des carbures et de l'austénite ;

la trempe dudit article cémenté ; et l'étape de trempe faisant intervenir la trempe de l'article à une température en dessous de la température de Ar₁ et au-dessus de la température de M_s du matériau en acier ; et

le maintien de l'article à une température en dessous de la température de Ar₁ et au-dessus de la température de M_s pendant une période suffisante pour transformer en bainite inférieure au moins 70 % environ de ladite austénite dans la microstructure d'aire présélectionnée.

2. Un procédé pour former un article en acier tel que revendiqué dans la revendication 1, dans lequel ladite étape de trempe consiste à former au moins 20 % environ de carbures sur la surface présélectionnée ayant une microstructure de matrice constituée d'au moins 70 % environ de bainite inférieure.

3. Un procédé tel que revendiqué dans la revendication 1 ou la revendication 2, dans lequel l'étape de cémentation fait intervenir :

la cémentation de l'article dans un premier stade ;

le refroidissement de l'article jusqu'à une température en dessous de la température de Ar₁ ; et,

de nouveau, la cémentation de l'article dans une atmosphère présentant une teneur en carbone à un niveau supérieur à la limite de saturation du carbone dans l'austénite.

4. Un procédé tel que revendiqué dans la revendication 3 dans lequel l'étape de refroidissement fait intervenir la trempe de l'article sous atmosphère gazeuse.

5. Un procédé tel que revendiqué dans la revendication 4, dans lequel la trempe sous atmosphère gazeuse est effectuée à une vitesse suffisante pour supprimer la nucléation de carbures sur la surface cémentée.

6. Un procédé tel que revendiqué dans n'importe laquelle des revendications précédentes, dans lequel, lors de l'étape de maintien de la température de l'article, la température est maintenue à sensiblement 25 °C au-dessus de la température de M_s.

7. Un article en acier cémenté réalisé à partir d'un matériau en acier qui est durcissable par cémentation et qui contient, en pourcentage en poids, de 0,08 à 0,35 de carbone et pas plus de 0,10 pourcent de silicium, l'article ayant une microstructure qui est caractérisée par une pluralité de carbures superficiels sur au moins une surface présélectionnée de l'article, les carbures superficiels étant dispersés dans une matrice de bainite inférieure.

8. Un article tel que revendiqué dans la revendication 7, dans lequel ledit matériau en acier contient moins de 1,1 pourcent environ de chrome.

9. Un article tel que revendiqué dans la revendication 7 ou la revendication 8, dans lequel ledit matériau en acier comprend, en pourcentage en poids, de 0,08 % à 0,35 % de carbone, de 0,3 % à 1,7 % de manganèse, moins de 0,10 % environ de silicium, moins de 1,1 % environ de chrome, de 0,2 % à 2,5 % environ d'éléments carburigènes, y compris ledit chrome, moins de 6 % d'agents de durcissabilité supplémentaires, moins de 1 % environ d'éléments d'affinage de grain et pas plus de 0,15 % environ de cuivre, le reste consistant en du fer et des impuretés à l'état de traces.

10. Un article tel que revendiqué dans n'importe laquelle des revendications 7 à 9, dans lequel lesdits carbures superficiels présentent une dureté de particule maximum d'environ 900 au moins équivalent à 500 gram Knoop, et un échantillon non entaillé dudit article préparé conformément à la norme ASTM E23 a une résistance d'au moins 50 joules, telle que mesurée sur un appareil de test d'impact Charpy à 25 °C.

11. Un article tel que revendiqué dans n'importe laquelle des revendications 7 à 10, dans lequel l'aire présélectionnée contient au moins 20 % environ de carbures, dispersés dans une matrice qui comprend au moins 70 % de bainite inférieure.

Drawing